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145 W PC Forward Converter
145 W PC Forward Converter
145 W PC Forward Converter
Specification
Application PC Main and PC Standby
Author PI Applications
Document
EPR-12
Number
Date 01-Feb-05
Revision 1.3
Objective
This document describes the operation and provides the performance data of a design
using TOP247 as a forward converter for 145 W PC supply application and TNY266 as a
10 W flyback for PC standby.
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EPR-12 – PC Forward Converter with Standby Flyback Power Supply 01-Feb-05
Table of Contents
Table of Contents............................................................................................................... 2
1 Introduction ................................................................................................................. 3
2 Supply Requirements.................................................................................................. 5
2.1 Power Supply Specification ..................................................................................... 5
2.2 Conditions for Cross Regulation Test...................................................................... 6
2.3 Output Characteristics ............................................................................................. 6
2.4 Transient Overshoot ................................................................................................ 6
2.5 Short Circuit Protection............................................................................................ 6
3 Schematics ................................................................................................................. 7
4 Circuit Description ..................................................................................................... 10
5 PCB Layout............................................................................................................... 12
6 Bill Of Materials......................................................................................................... 14
6.1 Electrical Bill of Materials....................................................................................... 14
6.2 Hardware Bill of Materials...................................................................................... 16
6.3 Output Cable Bill of Materials ................................................................................ 16
6.4 Heatsinks Bill of Materials ..................................................................................... 17
7 Transformer Specification ......................................................................................... 18
7.1 145 W Forward Transformer ................................................................................. 18
7.1.1 Electrical Specifications.................................................................................. 18
7.1.2 Materials......................................................................................................... 18
7.1.3 Transformer Build Diagram ............................................................................ 19
7.1.4 Transformer Construction............................................................................... 19
7.2 10 W PC Standby Transformer ............................................................................. 21
7.2.1 Electrical Specifications.................................................................................. 21
7.2.2 Materials......................................................................................................... 21
7.2.3 Transformer Build Diagram ............................................................................ 22
7.2.4 Transformer Construction............................................................................... 22
7.3 Output Coupled Inductor ....................................................................................... 23
7.3.1 The Toroid Layout .......................................................................................... 23
7.3.2 Inductances.................................................................................................... 23
7.4 The Mag Amp Inductor.......................................................................................... 24
7.4.1 Core Specification .......................................................................................... 24
7.4.2 Winding Instruction......................................................................................... 24
8 PIXls Design Spreadsheet ........................................................................................ 25
9 Test Results .............................................................................................................. 30
10 Performance Data..................................................................................................... 31
10.1 Efficiency and Regulation .................................................................................. 31
10.2 Power Limit vs. Input Line.................................................................................. 32
11 Waveforms................................................................................................................ 33
11.1 Drain Switching Waveforms............................................................................... 34
11.2 Output Ripple Measurements ............................................................................ 36
12 Conducted EMI ......................................................................................................... 37
13 Revision History ........................................................................................................ 38
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Important Note:
Although the EP-12 is designed to satisfy safety isolation requirements, this
engineering prototype has not been agency approved. Therefore, all testing should be
performed using an isolation transformer to provide the AC input to the prototype board.
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EPR-12 – PC Forward Converter with Standby Flyback Power Supply 01-Feb-05
1 Introduction
The following engineering report gives the detailed description and test data for a
TOP247 forward converter designed for 145 W PC main applications and a TNY266
flyback for PC standby. The requirements listed below are typical of a PC power supply.
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2 Supply Requirements
Environmental
Conducted EMI Meets CISPR22B / EN55022B
Designed to Meet IEC950,
Safety UL1950 Class II
1.2/50 µs Surge, IEC 1000-4-5,
Surge 4 kV 12 Ω Series Impedance,
Differential and Common Mode
100 kHz Ring Wave, 500 A Short
Surge 4 kV Circuit Current, Differential and
Common Mode
o
Ambient Temperature TAMB 0 50 C Free Convection, Sea Level
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a. Rise time: all outputs of the power supply must rise from 10% to 90% of their rated
output voltages within 2 ms to 20 ms at nominal line, maximum load.
c. Hold-up time: 16 ms minimum for all outputs at 110 VAC, 60 Hz, and full load.
The main supply shall latch off from a shorted output condition. The latch is reset through
toggling remote ON/OFF.
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3 Schematics
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4 Circuit Description
With line feed forward, duty factor reduction, programmable primary current limit, line-
sense for input UV and OV, and soft-start function for smooth start-up, the
TOPSwitch−GX family has all the needed functions to operate in an off-line, single-
ended forward converter configuration. Also the TOPSwitch−GX family has a sufficient
power capability to bring PC main applications easily within its reach.
In the present design the LINE-SENSE pin (L pin, please refer to TOPSwitch−GX data
sheet) senses the rectified DC input voltage through the combination of R3, R5, and R6
and inhibits the supply from switching until the minimum voltage of 80 VAC (doubled
mains) or 160 VAC is reached. Upon reaching this voltage and activation of switching,
current sourced from R8 will immediately establish a maximum duty factor limit by
injecting the appropriate amount of current into the LINE-SENSE pin (adjusting maximum
duty factor, please refer to TOPSwitch−GX data sheet). The input from R8 is a quasi-
integrated, DC-rectified forward voltage sourced from the bias winding and will restrict
the duty factor to a greater degree as the line voltage is increased. This is a very
significant function to ensure that the transformer will not saturate, even in extreme
transient load conditions.
A TOP247 was selected for this 145 W application and its primary current limit was
adjusted to limit at approximately 2.5 A by R12 when U3 is on. This allows approximately
170 W of peak output power.
Lowering the input voltage will cause the converter to shut off by means of the under-
voltage lockout circuit around Q1. When input voltage is low enough to bias on Q1, the
collector of Q1 will pull up the X pin of the TOP247 via R39 and shut off the main
converter.
This design uses a Zener primary clamp (D3, D4, D5) with a capacitor (C4) in parallel
that is coupled to the drain of the TOPSwitch−GX through a diode (D1). This is a very
efficient snubber as it allows the maximum flyback voltage to develop during the off time
which returns a significant amount of energy back to the transformer during the reverse
time recovery of the diode D1. The total dissipation of the primary snubber clamp circuit
was measured to be only 0.8 W at maximum load.
It is necessary to use voltage mode control in the regulation loop when using
TOPSwitch−GX. As the data will show, the transient response is very good and there
appears to be no difficulty in compensating the voltage mode control loop for optimal
performance.
The remote ON/OFF function is implemented by using a very simple circuit around Q3.
When the ON line (green wire in output cable) is grounded to secondary return, Q3 is
turned on and drives the LED of U3 on, which will ground R12 on the primary side and
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enable the TOP247 via its X pin. If the output comes up into regulation before C19
completely discharges, Q3 is sustained on through R28 and the converter remains
running. Upon loss of regulation, Q3 will turn off and the converter will shut off. Toggling
the ON/OFF input will allow the converter to retry operation.
When the ON line is open, it is internally pulled up to the +5 V standby and the main
converter remains in the inhibit state. The +5 V standby is always operating provided
there is sufficient AC input to the supply. By connecting the ON line to output return, the
main supply will turn on, provided there is sufficient input voltage and there is no fault
condition. If there is a fault then the supply will latch off. A retry is accomplished by
simply toggling the ON line.
Note: If the remote ON line is connected to output return (main power enabled) while
turning on AC into the supply, the main converter will automatically turn on. However, if
AC is brought up too slowly (i.e. adjusting a variac), the supply will not turn on and the
ON line will have to be toggled to turn on the supply. The output interconnect board
provided has the ON line already connected to an ON/OFF switch for manual
ON/OFF control via the ON line.
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5 PCB Layout
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6 Bill Of Materials
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7 Transformer Specification
Electrical strength 60 Hz, 1 min, from Pins 1-7 to Pins 10-14 3000 VAC
Primary Inductance All windings open 4.5 mH or Higher
Resonant Frequency All windings open 0.2 MHz minimum
Primary leakage inductance Pins 6-14 shorted 8 µH maximum
7.1.2 Materials
Item Description
[1] Core: PC40 EER28L
[2] Bobbin: BEER28L-1114CPH
[3] Magnet Wire: #28 AWG Heavy Nyleze
[4] Magnet Wire: #30 AWG Heavy Nyleze
[5] Magnet Wire: #20 AWG Heavy Nyleze
[6] Copper ribbon .670″ x .008″
[7] Tape: 3M 1298 Polyester Film (white) 21.8 mm wide by 2.2 mils thick
[8] Tape: 3M 1298 Polyester Film (white) 15.8 mm wide by 2.2 mils thick
[9] Tape: 3M 44 Margin tape (cream) 3.0 mm wide by 5.5 mils thick
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Margin Taping Use item [9] for the right and left margins.
Start at pin 5. Wind 45 turns of item [3] from left to right. Wind
Primary Winding
uniformly in a single layer. End at pin 1.
Basic Insulation 1 Layer of tape [8] for basic insulation.
Margin Taping Use item [9] for the right and left margins.
Start at pin 3. Wind trifilar 6 turns of item [4] from left to right.
Bias Winding Wind uniformly in a single layer, across entire width of bobbin.
Finish on pin 7.
Reinforce Insulation 3 Layers of tape [7] for insulation.
Prepare copper ribbon [6] as shown in Figure 10. Match pin A
Copper Foil Winding of the foil to pin 11 or 12 of the bobbin. Wind 3 turns of item
(5 V) [6]. Finish by matching pin B of the foil to pins 8 and 9 of the
bobbin.
Reinforce Insulation 3 Layers of tape [7] for insulation.
Margin Taping Use item [9] for the right and left margins.
Start at pin 13. Wind 4 turns of item [5] from left to right. Wires
12 V Winding
are populated in middle of bobbin. Finish at pin 14.
Outer Insulation 3 Layers of tape [7] for insulation.
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Electrical Strength 1 min, 60 Hz, from pins 1-4 to pins 5-10 3000 VAC
Primary Inductance All windings open 2.3 mH
Resonant Frequency All windings open 800 kHz minimum
Primary Leakage Inductance Pins 6-10 shorted 130 µH maximum
7.2.2 Materials
Item Description
[1] Core: EE16
[2] Bobbin: BE-16
[3] Magnet Wire: #35 AWG Heavy Nyleze
[4] Triple Insulated Wire: #26 AWG
[5] Magnet wire #30 AWG heavy Nyleze
[6] Tape: 3M 1298 Polyester Film (white) 9.0 mm wide by 2.2 mils thick
[7] Varnish
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Start at Pin 7. Wind 158 turns of item [3] from left to right, then from right to left
Primary Layer until done. It takes about 3 1/4 layers. Apply 1 layer of tape, item [5] between each
winding layer for basic insulation. Finish the wiring on Pin 5.
Insulation 1 Layer of tape [6] for insulation.
Bias Winding Start at pin 9. Wind 17 turns of item [5] from left to right. Finish on pin 10.
Insulation 1 Layer of tape [6] for insulation.
Start at Pin 2. Wind 7 bifilar turns of item [4] from left to right. Wind uniformly, in a
Secondary Winding
single layer, across entire width of bobbin. Finish on Pin 1.
Outer Insulation 3 Layer of tape [6] for insulation.
Final Assembly Assemble and secure core halves. Impregnate uniformly [7].
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Figure 14 - The Side View. Figure 15 - Bottom Plate Viewed from Top.
(Measurements are in inches). (Measurements are in inches).
7.3.2 Inductances
Note:
1 All dimensions are ±0.02”
2 Core = T 106 – 26
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Core Number OD ID HT
MP1305P-4AS 14.4 mm 7.9 mm 6.6 mm
Use number 18 AWG wire (heavy gauge Nyleze wire) to wind 7 turns around the
core as shown in Figure 18. Leave the wire legs about 1″ long.
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DIODE Vf SELECTION
Main output rectifiers forward voltage drop
VDMAIN 0.5 Volts
(Schottky)
Magamp output rectifiers forward voltage
VDMAINMA 0.5 Volts
drop (Schottky)
Auxiliary output rectifiers forward voltage
VDAUX1 0.7 Volts
drop (Ultrafast)
Independent output rectifiers forward voltage
VDIND1 0 Volts
drop (Schottky)
VDB 0.7 Volts Bias output rectifier conduction drop
TRANSFORMER DESIGN
PARAMETERS
NP 45 45 Primary rounded turns
Bias turns to maintain 8V minimum input
NB 6
voltage, light load
Auxiliary rounded turns (DC stacked on
NAUX1 4
Main winding)
Approx. Aux output voltage with NASUX1 =
VAUX1 ACTUAL 11.63 Volts
4 Turns and DC stack
Independent rounded turns (separate
NIND1 0
winding)
Approximate independent output voltage
VIND1 ACTUAL 0.00 Volts
with NIND1 = 0 turns
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CURRENT WAVESHAPE
PARAMETERS
Maximum peak primary current at maximum
IP 2.451 Amps
DC Bus voltage
Maximum primary RMS current at minimum
IPRMS 1.460 Amps
DC Bus voltage
Optocoupler
VCEO OPTO 49.8 Volts Maximum optocoupler collector-emitter
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voltage
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DX_MAX
D_RESET
D_ACTUAL DX_MIN
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9 Test Results
Thermal and Dissipation Data
The unit was enclosed in a standard ATX enclosure. The ambient external temperature
around the enclosure was 25 °C and the internal ambient in the enclosure in the box
near TOP247 heatsink was measured 37 °C.
The TOP247 source tab temperature for above conditions was measured 53 °C.
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10 Performance Data
Note: 12 V load table does not include the 100 mA internal load, which is equivalent to
fan loading.
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EPR-12 – PC Forward Converter with Standby Flyback Power Supply 01-Feb-05
179
Total Ouptut Power
178
177
176
(Watts)
175
174
173
172
171
90 100 110 120 130 140
AC Input (Volts)
Blue Angel
240 VAC input, main converter inhibited, +5 V standby loaded to 2.5 A.
Input power is 4.2 W.
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11 Waveforms
3.3 V Output
Figure 21 – Primary Drain Current at Start-up, Figure 22 – +5 V and 3.3 V Rise at Turn-on from
Activated from Remote ON/OFF Remote ON/OFF , 120 VAC Input,
with 120 VAC Input. 5 V out at 12 A, 3.3 V at 12 A,
0 A on +12 V.
5 V Standby
5 V Main
5 V Standby
5 V Main
Figure 23 – 5 V Main and 5 V Standby Start-up Figure 24 – 5 V and 5 V Standby Drop out After
(120 VAC). Max Load on all Outputs. AC off Max Load on 5 V Standby, Min
Load on all Other Outputs.
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5 V @ 12 A, 3.3 V @ 12 A, 12 V @ 3 A
Figure 25 – Drain to Source Voltage of TOP247 Figure 26 – Drain to Source Voltage of TOP247
at 220 VAC. at 165 VAC.
Figure 27 – Drain to Source Voltage of TOP247 Figure 28 – Drain to Source Voltage of TOP247
at 270 VAC. at 270 VAC Input 3.3 V Output
Shorted at PC Board.
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5 V Standby
5 V Output
Figure 29 – 110 VAC Applied Line Terminated Figure 30 – Drain Switching Voltage of TNY266
with Following Loads: 5 V at 13 A, (PC Standby) 230 VAC Input
3.3 V at 12 A, 12 V at 3.5 A. 5 V Loaded to 1.5 A.
+ 5 V Standby Output
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12 Conducted EMI
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13 Revision History
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Notes
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Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any
information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER
INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES
INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
PATENT INFORMATION
The products and applications illustrated herein (including circuits external to the products and transformer construction) may be
covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power
Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch and EcoSmart are registered trademarks of
Power Integrations. PI Expert and PI FACTS are trademarks of Power Integrations. © Copyright 2005 Power Integrations.
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